Post-consumer scrap film recycling system and process

ABSTRACT

A system for processing a supply of post-consumer scrap linear low density or low density polyethylene film into near-virgin quality blown film product. The system includes tearing the supply of film in a shredder, wherein the surface area of the film is exposed, including delaminating the film. The torn supply of film is washed in a hot water bath including a surfactant. The film is agitated in the bath containing the surfactant wherein contaminants on the film are removed from the film. The washed film is ground into smaller pieces and additional washing of the ground film in a rotating friction washer occurs wherein additional contaminants are removed from the film. The ground film is then dried in a dryer and compacted in a compactor without addition of water into granulated objects of near-virgin quality blown film product.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/029,951, filed on Sep. 18, 2013, now U.S. Pat. No. 8,690,090, grantedon Apr. 8, 2014, entitled “Post Consumer Scrap Film Recycling System,”which in turn is a continuation of U.S. patent application Ser. No.13/024,088, filed on Feb. 9, 2011, now U.S. Pat. No. 8,567,702, grantedon Oct. 29, 2013, entitled “Post Consumer Scrap Film Recycling Process,”both of which patent applications hereby incorporated herein byreference in their entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates generally to a system and a process forrecycling scrap, and more particularly to a system and a process forrecycling post-consumer scrap linear low density polyethylene film andpost-consumer low density polyethylene film.

Recycling of post-consumer plastic waste has received considerablepublicity as being environmentally correct and “green.” It is known thatthe majority of municipal, mixed post-consumer plastic waste includespolyethylene perephthalathe (“PET”) materials, such as used in sodabottles and unpigmented high density polyethylene (“HDPE”) materials,such as milk bottles. In a typical recycling procedure, the containerscomposed of PET and HDPE are separated from other waste and are thenshredded into smaller pieces, cleaned, heated, and extruded orgranulized for reuse as other products.

One type of post-consumer (“PC”) scrap that has been difficult torecycle is polyethylene film. Typically, PC film material is a “stretchwrap” linear low density polyethylene (“LLDPE”). Because of the strengthcharacteristics and the stretch characteristic of the LLDPE, such filmis used as a baling material and as a wrap material for palletized loadsor baling processes. Another type of PC film is low density polyethylene(“LDPE”), which is used as a wrap and for bags.

LLDPE film is used in wrapping and securing boxes, containers, orsimilar items on a pallet during shipping. Upon arrival at a givendestination, such PC film is removed from the palletized materials andscrapped. Such PC film typically has labels that are glued onto theoutside of the film as well as various markings that are placed on thefilm during the shipping process. The PC film typically is wrappedaround the materials on the pallets several times so that there arelayers upon layers of the PC film.

PC film is also used to bale other scrap material. When PC film isremoved from the pallets or other bales, because of the high level ofcontamination such as dirt, oil, biological material, layering, labeladhesives, etc. the PC film is either tossed in a landfill or processedas a filler for other plastic products. Reuse of the PC film as a viableblown film product for use as industrial film or a bag product hasgenerally not been instituted. Typically, such used film has limited usedue to high levels of contamination present which, in turn, causessevere processing issues as well as unpleasant properties in thefinished product, for example, odor, discolorations and a “pitted”appearance.

The apparatus implementing the present disclosure must also be ofconstruction which is both durable and long lasting, and it should alsorequire little or no maintenance to be provided by the user throughoutits operating lifetime. In order to enhance the market appeal of theapparatus of the present disclosure, it should also be of inexpensiveconstruction to thereby afford it the broadest possible market. Finally,it is preferable that some or all of the aforesaid advantages andobjectives be achieved without incurring any substantial relativedisadvantage.

The subject matter discussed in this background of the invention sectionshould not be assumed to be prior art merely as a result of its mentionin the background of the invention section. Similarly, a problemmentioned in the background of the invention section or associated withthe subject matter of the background of the invention section should notbe assumed to have been previously recognized in the prior art. Thesubject matter in the background of the invention section merelyrepresents different approaches, which in and of themselves may also beinventions.

SUMMARY OF THE INVENTION

The disadvantages and limitations of the background art discussed aboveare addressed by the process of the present disclosure.

There is provided a process which may be implemented in an associatedsystem for processing a supply of post-consumer scrap linear low densitypolyethylene film or low density polyethylene film into near-virginquality blown film product. The system includes a shredder configured totear the supply of multilayered film in the shredder. The shredderexposes the surface area of the film and delaminates the film. The tornfilm then goes into a water bath apparatus configured to wash the tornfilm in the water bath, which includes a surfactant and which agitatesthe film in the bath. Contaminates are removed from the delaminated filmin the water bath.

From the water bath, the film is moved into a grinder which isconfigured to grind the film. The ground film is then moved to aplurality of rotating friction washers configured to wash the groundfilm, wherein additional contaminants are removed from the film. A dryeris configured to dry the ground film, resulting in the ground filmcontaining not more than 10% by weight, water content. The dried film iscompacted in a compactor configured to compact the dry, ground film,without additional water, into granulated objects of mere virgin qualityblown film product. A conveyor network interconnects the various systemequipment, with the conveyor network including one of a storageconveyor, an inclined conveyer, a discharge belt, a transport screw, anda pneumatic transport tube.

In another embodiment, the water bath may include a plurality of washerswith at least one washer containing hot water. In a washer that containshot water, the hot water is at least 140 degrees Fahrenheit and not morethan 190 degrees Fahrenheit.

In another embodiment, the system includes a detector configured todetect metal in the supply of film, and includes subjecting the supplyof film to a magnetic field to identify ferrous metal. Any ferrous metaldetected is removed from the supply of film by a machine or by manualremoval. The system may also include a detector configured as an X-raymachine to detect a non-film object.

The system may also include a granulator that is configured to form thegranulated objects into pellets after they are compacted by thecompactor.

There is further provided a system for processing post-consumer scrapfilm into a near virgin quality blown film product, with the filmincluding one of a supply of multi-layer recyclable linear low densitypolyethylene plastic film and a supply of multi-layer recyclable lowdensity polyethylene plastic film.

The system includes a detector configured to detect a non-film object inthe supply of film. The detector may be configured as one of an X-rayproducing apparatus and a magnetic field producing apparatus. The systemfurther includes a machine configured to remove the non-film objectdetected in the film. The removal can be by machine or manual removal.The system includes a shredder configured to shred the supply ofmulti-layer plastic film after removal of the non-film object and totear the shredded film exposing delaminated surface areas of the film. Afilter screen is configured to receive and filter the shredded plasticfilm.

A water bath apparatus is configured to receive the filtered film fromthe filter screen. An agitator is coupled to the water bath apparatusand configured to agitate the water in the water bath apparatus tofurther delaminate and wet all surfaces of the shredded plastic film.

A wet grinder apparatus is configured to receive the shredded plasticfilm from the water bath, with the wet grinder configured to grind theplastic film. A rotating friction washer is configured to receive thewet ground plastic film, with the rotating friction washer configured towash the ground plastic film wherein contaminants are removed. A cycloneapparatus is configured to receive the ground plastic film from therotating friction washer, with the cyclone configured to separate alight, by weight, plastic film from a heavy, by weight, plastic film.

A pair of dryer apparatuses may be used, with one dryer apparatusconfigured to receive the light plastic film and one dryer apparatusconfigured to receive the heavy plastic film, with both dryerapparatuses configured to dry the plastic film so that the film containsnot more than 10%, by weight, water content.

A compactor apparatus is configured to compact the dried plastic filmreceived from the dryer apparatus, without the addition of water, intogranulated objects of near virgin quality plastic, and the granulatedobjects may then be stored in a storage apparatus configured to receivethe granulated objects of near virgin quality plastic film.

The method of processing the supply of film may include at least one ofthe washing processes using hot water having a temperature of at least140° F., but not more than 190° F. During the process, metal may bedetected in the supply of film and removed from the supply prior to thegrinding process.

There is also provided a method for processing post-consumer scrap filminto a near-virgin quality material suitable for a blown film product.The method includes providing one of a supply of recyclable linear lowdensity polyethylene plastic film and a supply of low densitypolyethylene plastic film and removing the metal from the supply ofplastic film. The plastic film is shredded after metal removal with theshredding process tearing the plastic film and exposing the surface areaof the film. The shredded plastic film is discharged through a filterscreen to a water bath, wherein the shredded plastic film is agitated towet all the surfaces of the shredded plastic film. The plastic film isthen removed from the water bath and a wet grinding of the plastic filmoccurs.

The ground plastic film is washed again in a rotating friction washer,wherein contaminants are removed from the plastic film. At least twodifferent types of the washed ground plastic film is separated in ahydrocyclone, wherein lighter plastic film is separated from heavierplastic film. The ground plastic film is dried and compacted, withoutthe addition of water, into granulated objects of near-virgin qualitylinear low density polyethylene plastic and near-virgin quality lowdensity polyethylene plastic. The granulated objects are then eitherstored or used as raw material in a blown film operation.

There is further provided a method for processing post-consumer scrapfilm into a near-virgin quality material suitable for a blown filmproduct. The method includes providing one of a supply of recyclablelinear low density polyethylene plastic film and a supply of low densitypolyethylene plastic film and removing the metal from the supply ofplastic film. The plastic film is then shredded after metal removal,wherein the plastic film is torn exposing the surface area of the film.The shredded plastic film is discharged through a filter screen to awater bath, wherein the film is agitated to wet all the surfaces of theshredded plastic film. The water bath includes a surfactant, forexample, a detergent additive to assist in removal of contaminants. Thewashed plastic film is removed from the water bath and wet ground. Theground plastic film is washed again in a rotating friction washer, whereadditional contaminants are removed from the plastic film.

The plastic film may be subjected to a hydrocyclone for separating atleast two different types of the washed ground plastic film. The lighterplastic film is separated from heavier plastic film in the hydrocyclone.The ground plastic film is dried so that it contains not more than 10percent, by weight, water content. The dried ground plastic film iscompacted, without the addition of water, into granulated objects ofnear-virgin quality polyethylene plastic, and is either stored or usedas raw material in a blown film operation. The granulated plastic filmcan also be formed into pellets after the compacting step.

The apparatus to implement the present disclosure is of a constructionwhich is both durable and long lasting, and which will require little orno maintenance to be provided by the user throughout its operatinglifetime. The apparatus of the present disclosure is also of inexpensiveconstruction to enhance its market appeal and to thereby afford it thebroadest possible market. Finally, all of the aforesaid advantages areachieved without incurring any substantial relative disadvantage.

DESCRIPTION OF THE DRAWINGS

These and other advantages of the present invention are best understoodwith reference to the drawings, in which:

FIG. 1 is a flow chart of an exemplary embodiment of a process that maybe used to recycle post-consumer (“PC”) scrap film; and

FIG. 2 is a schematic top view of an apparatus configured to process PCfilm in accord with some, but not all, of the process steps shown in theflow chart illustrated in FIG. 1.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

There is provided a method and apparatus for recycling post-consumer(“PC”) scrap such as PC film which is difficult to recycle because oflabels that are glued on the outside of the film as well as variousmarkings that are placed on the film during the shipping process andother contaminates. In order to provide a viable blown film product thatcan be reused, the labeling, adhesives, other applied markings, andcontaminates have to be removed from the PC film. It is the objective ofthe present disclosure to process the PC film (LLDPE and LDPE) into anear-virgin quality blown film product that can be used by itself orcombined with virgin material.

For purposes of this application the term “near-virgin” shall mean aquality of the PC film compared to virgin material of blown filmproduct. A test for such quality is a visual gel detection test. Forpurposes of this Application a “gel” is an unmelted portion of PC filmor unmelted contaminate. In the test, the numbers of gels, independentof their size, are determined on a 12 inch by 12 inch square sample.Virgin material has a gel count of between 0 gels and 10 gels.Near-virgin material has a gel count of between 11 gels and 1,000 gels.Conventional PC product has a gel count that is much, much higher thanthe gel count of such near-virgin material. The Applicants have compareda conventional PC product to a PC product produced with the process andthe system of the present disclosure, as summarized in the followingtable:

Film Type Gel Count (Range) Gel Count (Typical) Conventional PC Very,Very High 52,740 Present Disclosure PC 11-1000 720 Virgin Material 0-10 9

Referring to the drawings, FIG. 1 is a flow chart of an exemplaryembodiment of a preferred process for recycling post-consumer scrap filminto a near-virgin quality blown film product. FIG. 2 is a schematic topview of exemplary embodiment of a system that may be configured toprocess PC film (through the addition of additional elementscorresponding to the process steps shown in the flow chart illustratedin FIG. 1). It should be understood that the physical layout of theequipment, as illustrated in FIG. 2, is general in nature and exemplaryof systems useful to process plastic scrap, and that otherconfigurations requiring additional equipment as well as alternateequipment layouts are contemplated that require additions of equipmentto or different arrangements of equipment within the boundaries of thegeneral system layout shown in FIG. 2 to perform the processes describedherein.

A supply of post-consumer scrap linear low density polyethylene(“LLDPE”) film or low density polyethylene (“LDPE”) film or acombination of LLDPE and LDPE film (hereinafter “PC film 12”) is placedonto a storage conveyor 14. Placement of the supply of PC film 12 on thestorage conveyor 14 can be by any convenient and conventional methodsuch as a forklift, crane, hoist, and in some instances manualdisposition. The storage conveyor 14 moves the supply of PC film 12 toan inclined conveyor 15.

The supply of PC film 12 typically is presented in bales held togetherby retainer bands. In a typical operation, the retainer bands are cutand the bale is pulled apart for initial visual inspection. Such processcan be done manually, or by a machine, as determined by the operator. Ifany non-film objects are initially seen in the supply of PC film 12,such objects may be removed either manually or by machine.

The unbaled supply of PC film 12 is then moved by the storage conveyor14 to an inclined conveyor 15 through or near a metal detector 16(referred to in FIG. 1 as a metal detector conveyor since the metaldetector is used in conjunction with the inclined conveyor 15) tofacilitate removal of certain forms of metal. The metal detector 16typically is an induction metal detector which has several forms ofmagnets, for example electromagnets, to detect and assist in removal offerrous materials automatically. It is also contemplated that a seriesof permanent magnets within appropriate distances to the supply of PCfilm 12 can be used to detect and/or remove ferrous metal objects. Othertypes of detectors, for example an X-ray machine, can also be used todetect non-film objects.

The inclined conveyor 15 moves the supply of PC film 12 to a shredder18, for example a Vecoplan or Wiema shredder, that is configured totear-shred the PC film into chunks and pieces and discharge the shreddedfilm through a screen. The screen size and the resultant film surfacearea may vary depending upon operational requirements. One example of ascreen is one that has a plurality of 3-inch openings.

The shredder 18 is configured to tear the supply of PC film 12 wherein asurface area of the PC film 12 is exposed. The shredder 18 alsodelaminates the film. Because of typical shipping wrap process, the PCfilm 12 is layered one layer on top of another layer and the shredder 18is configured to delaminate such layers, i.e. separate the film layersfrom one another. A shredder configured to cut the film typically fusesthe film layers, making cleaning the film difficult, if not impossible.

The shredded supply of PC film 12 is moved by a discharge conveyor to afirst washing (and transport) screw 22. The first washing screw 22 wetsthe shredded PC film 12 during resonance time of the PC film 12 in thefirst washing screw 22, and then conveys the wetted, shredded PC film 12to a prewash/sink/float tank apparatus 24. While in theprewash/sink/float tank apparatus 24, further separation of high densitymaterials not recognized by the metal detector 16, for example stone,glass, or sand, occurs, since they sink to the bottom of theprewash/sink/float tank apparatus 24 for later removal. While in theprewash/sink/float tank apparatus 24, the shredded PC film 12 is furtherwetted by agitation, performed, for example, by a series of rotatingpaddles.

Additional cleaning of the shredded PC film 12 is accomplished while inthe prewash/sink/float tank apparatus 24 or subsequently by surfactantssuch as, for example, detergents and other compounds mixed into theprewash/sink/float tank apparatus 24 to further clean the film ofcontaminants such as inks, adhesives, etc.

Surfactants are substances that are added to liquids to reduce thesurface tension of the liquid, thereby increasing the liquid's spreadingand wetting properties. Surfactants are used, for example, to disperseaqueous suspensions of insoluble dyes. Such additives may also softenadhesives used to attach labels to the PC film 12. A preferredsurfactant will include a detergent, an oxidizer, and a bleaching agent.It should be understood that the surfactant may include other chemicalsor additives, including ionic and non-ionic agents. In addition to thecleaning of the shredded PC film 12 while in the prewash/sink/float tankapparatus 24, the agitation also promotes delamination of the shreddedPC film 12, which has a tendency to stick to itself.

After a period of time as determined by the operator, the PC film 12fragments are conveyed to a wet grinder 26 (also known as a firstgranulator). The wet grinder 26 grinds the PC film 12 and furtherreduces in size the PC film 12 area received from the shredder 18 andthe prewash/sink/float tank apparatus 24. A typical particle size afterthe grinding or granulation process in the wet grinder 26 isapproximately three-quarters of an inch. The grinding or granulationprocess in the wet grinder 26 also promotes further separation of wetlabels from the PC film 12 substrate. From the wet grinder 26, theground or granulated particles of PC film 12 are conveyed to a firstfriction washer 28.

The granulated particles of PC film 12 are washed in the first frictionwasher 28, which is configured with an inclined cylindrical trough andan inclined fast-running paddle screw to dewater and clean thegranulated particles of PC film 12 discharged from the wet grinder 26.The inclined paddle screw is fixed in the housing of the friction washer28 by means of bearings, and is enclosed in a stainless steel screen.The shredded and granulated particles of PC film 12 and water are fed atthe lower end of the trough, with the inclined paddle screw transportingthe material upward, and spinning at a high speed, for example 1,000rpm.

The granulated particles of PC film 12 are washed in the first frictionwasher 28 while they are being transported to an outlet at the top ofthe trough of the first friction washer 28. The contaminates and thewater are passed through the fine stainless steel screen to the troughwall, while the friction of the high speed screw further cleans thegranulated particles of PC film 12. Following the first friction washer28 is a second washing screw 22 which provides additional resonance timefor the granulated particles of PC film 12 therein. Following the secondwashing screw 22 is a turbo washer 30 to provide additional cleansing ofthe granulated particles of PC film 12 and separation of contaminantsfrom the PC film 12. Following the turbo washer 30 is a second frictionwasher 28 that washes the granulated particles of PC film 12 therein.

Operation of the first turbo washer 30 (as well as the second washingscrew 22 and the second friction washer 28) can be either with coldwater or hot water. In the case of a hot water bath, the temperature canbe in the range of 120° F. to 190° F., with the preferred temperaturebeing a water temperature of at least about 140° F. but not more thanabout 190° F. The hot water is used to affect additional cleaning of thegranulated particles of PC film 12 in the washer in addition to therotary motion imparted to the granulated particles of PC film 12.Temperatures over 190° F. tend to distort and/or melt the granulatedparticles of PC film 12.

It should be understood that friction washers 28 can be positioned inmultiple different locations, such as in front of or after washing tanks(or in both such locations). As illustrated in the preferred embodimentof FIG. 1, friction washers 28 are positioned both before and after theturbo washer 30. A third friction washer 28 is also positioned after theeven later in the process illustrated in FIG. 1.

Following the second friction washer 28, the granulated particles of PCfilm 12 are deposited in a first turbo dryer 40. The first turbo dryer40 removes moisture from the granulated particles of PC film 12. Thegranulated particles of PC film 12 next move to a second turbo washer 30wherein they are in effect rinsed with water. The rinsed granulatedparticles of PC film 12 are then moved (e.g., by a pump 32 as shown inFIG. 2) to a water cyclone, which is generally referred to as ahydrocyclone 34, such as for example a hydrocyclone 34 of the typeproduced by Herbold Meckesheim. The hydrocyclone 34 operates under waterpressure from the pump 32 which moves water in a spiral to furtherseparate contaminates from the granulated particles of PC film 12 andfurther separate layers of the granulated particles of PC film 12 byrotational forces of the moving water within the hydrocyclone 34.

The granulated particles of PC film 12 leave the hydrocyclone 34 at itsupper end with the main stream of water, with any sinking material(higher density material) at the lower end. The hydrocyclone 34 operatesin conjunction with the pump 32 and the turbo washer 30 to provideadditional cleansing of the granulated particles of PC film 12 andseparation of contaminants from the granulated particles of PC film 12.The water from the hydrocyclone 34 continues to transport the granulatedparticles of PC film 12 to (a vibrating screening apparatus 38 shown inFIG. 2 and then to) a third friction washer 36.

Upon exiting the third friction washer 36, the granulated particles ofPC film 12 are deposited into second and third turbo dryers 40. Thesecond and third turbo dryers 40 removes moisture from the granulatedparticles of PC film 12. (Referring to FIG. 2, a pneumatic transportsystem 42 may be used to move the granulated particles of PC film 12between components.) The third turbo dryer 40 removes additionalmoisture from the granulated particles of PC film 12. The granulatedparticles of PC film 12 now are typically in the form of flakes whichare then deposited into a film flake buffer silo 48.

Additional drying could optionally be performed in a thermal dryingapparatus 46 (shown in FIG. 2) which uses heat to remove additionalmoisture from the flakes of PC film 12. In FIG. 2, a series of pneumatictransport systems 42 interconnect the various dryers and the film flakebuffer silo 48. It should be understood that additional turbo dryersand/or thermal drying apparatuses could be installed in the system andcoupled with the pneumatic transport systems.

From the film flake buffer silo 48, the flakes of PC film are moved(e.g., via a pneumatic transport system 42) to additional processingapparatus including a plastcompactor 50, which may be any commerciallyavailable such device. In one such plastcompactor 50, a rotating diskand a fixed compaction disk are used with both disks configured withscrew-fitted and replaceable kneading rails. The flakes of PC film 12are conveyed continuously from the film flake buffer silo 48 through thecenter of the fixed disk into the processing area of the plastcompactor50 by means of a feed screw. The material is rapidly heated up by thefriction against and between the compactor disks. During the operationin the plastcompactor apparatus, the flakes of PC film are warmed upbecause of friction and start to soften. The surfaces of the flakes ofPC film 12 start to fuse, resulting in worm-shaped formations. Theadditional heating in the plastcompactor 50 further reduces moisture inthe worm-shaped formations of PC film 12. In a typical operation of themethods described herein, the PC film 12 has a moisture content of notmore than 10% by weight.

From the plastcompactor apparatus 50, the worm-shaped formations of PCfilm 12 are moved to a second granulator 52 which reduces theworm-shaped formations of PC film 12 to the required agglomeratedgranulated object size. The specific size of the agglomerated granulesof PC film 12 is selected by changing a screen inside the secondgranulator 52. The second granulator 52 further removes any additionalmoisture from the granules of PC film 12 and compacts the dry groundgranules of PC film 12, without addition of water, into granulatedobjects of near-virgin quality blown film product.

In one embodiment of the method, a controller 54 is used to control thevarious functions of the apparatus including water temperatures, airpressures, time periods, the specific machine granular size, and thespeed of operation.

The controller 54 may be a microprocessor coupled to the variousapparatus of the system. The controller 54 may also be a server coupledto an array of peripherals, or a desktop computer, or a laptop computer,or a smart-phone. It is also contemplated that the controller may beconfigured to control each individual machine, and may be remote fromany of the apparatus. Communication between the controller 54 and thevarious apparatuses may be either by hardwired or wireless devices. Amemory/database coupled to the controller 54 may be remote from thecontroller 54. The controller 54 typically includes one or more inputdevices, for example a mouse and/or a keyboard, and a display device,for example a monitor screen or a smartphone. Such devices can behardwired to the controller or connected wirelessly with appropriatesoftware, firmware, and hardware. The display device may also include aprinter coupled to the controller 54. The display device may beconfigured to mail or fax reports as determined by a user. Thecontroller 54 may be coupled to a network, for example, a local areanetwork or a wide area network, which can be one of a hardwired networkand a wireless network, for example a Bluetooth network or an Internetnetwork, for example, by a WI-FI connection or a “cloud” connection.

In another embodiment a water treatment apparatus 60 is coupled to thevarious wash apparatus to recycle and filter the water used within thesystem for continued use. The quality of the water will vary at variousstages of the process, with the recycling and filtering of the watercontrolled by the operator and/or in conjunction with the controller 54.

In a further embodiment, one or more testing stations may be installedto test the quality of the PC film 12 being processed. One such test isthe “gel count” test described above. However, other appropriate testscan be implemented as determined by the operator. The test stations canbe coupled to the controller 54 to automatically monitor, test, andreport results by configuring the controller 54. Testing is typicallyperformed at various stages of the process as determined by theoperator.

For purposes of this disclosure, the term “coupled” means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or moveable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or the two componentsand any additional member being attached to one another. Such adjoiningmay be permanent in nature or alternatively be removable or releasablein nature.

Although the foregoing description of the present process and system hasbeen shown and described with reference to particular embodiments andapplications thereof, it has been presented for purposes of illustrationand description and is not intended to be exhaustive or to limit thedisclosure to the particular embodiments and applications disclosed. Itwill be apparent to those having ordinary skill in the art that a numberof changes, modifications, variations, or alterations to the process andsystem as described herein may be made, none of which depart from thespirit or scope of the present disclosure. The particular embodimentsand applications were chosen and described to provide the bestillustration of the principles of the process and system and theirpractical application to thereby enable one of ordinary skill in the artto utilize the process and system in various embodiments and withvarious modifications as are suited to the particular use contemplated.All such changes, modifications, variations, and alterations shouldtherefore be seen as being within the scope of the present disclosure asdetermined by the appended claims when interpreted in accordance withthe breadth to which they are fairly, legally, and equitably entitled.

While the current application recites particular combinations offeatures in the claims appended hereto, various embodiments of theinvention relate to any combination of any of the features describedherein whether or not such combination is currently claimed, and anysuch combination of features may be claimed in this or futureapplications. Any of the features, elements, or components of any of theexemplary embodiments discussed above may be claimed alone or incombination with any of the features, elements, or components of any ofthe other embodiments discussed above.

What is claimed is:
 1. A system for processing a supply of post-consumerscrap linear low density polyethylene film or low density polyethylenefilm into near-virgin quality blown film product, comprising: a shredderconfigured to tear the supply of post-consumer scrap linear low densitypolyethylene film or low density polyethylene film in the shredder,wherein surface area of the film is exposed, including delaminating thefilm; a water bath configured to wet and agitate the torn film in thewater bath to remove contaminates from the delaminated film; a grinderconfigured to grind the wetted, delaminated film into ground film toreduce it in size; at least one washing device configured to wash theground film to remove additional contaminates from the ground film,wherein the at least one washing device contains hot water; wherein oneof the water bath or the at least one washing device includes asurfactant; at least one dryer configured to dry the ground film intoflakes of film containing not more than 10% by weight of water content;and additional processing apparatus configured to process the flakes offilm into granulated objects of near-virgin quality blown film product.2. The system of claim 1, additionally comprising: a metal detectorconfigured to detect metal in post-consumer scrap linear low densitypolyethylene film or low density polyethylene film prior to providing itto the shredder.
 3. The system of claim 2, wherein the metal detectorsubjects the post-consumer scrap linear low density polyethylene film orlow density polyethylene film to a magnetic field to identify ferrousmetal, wherein the system additionally comprises: a machine configuredto remove detected ferrous metal.
 4. The system of claim 2, additionallycomprising: a manual removal station configured to facilitate a manualremoval of detected metal.
 5. The system of claim 1, additionallycomprising: a detector configured as an X-ray machine to detect anon-film object in the post-consumer scrap linear low densitypolyethylene film or low density polyethylene film.
 6. The system ofclaim 1, wherein the water bath comprises: a prewash/sink/float tankapparatus that separates high density materials from the delaminatedfilm.
 7. The system of claim 6, wherein the water bath additionallycomprises: a first washing screw that initially wets the delaminatedfilm received from the shredder and then conveys the wetted, delaminatedfilm to the prewash/sink/float tank apparatus.
 8. The system of claim 1,wherein the at least one washing device comprises: a first frictionwasher; and a first turbo washer.
 9. The system of claim 8, wherein theat least one washing device additionally comprises: a second washingscrew located intermediate the first friction washer and the first turbowasher; and a second friction washer located subsequent to the firstturbo washer.
 10. The system of claim 1, wherein the hot water is atleast about 140 degrees Fahrenheit, but not more than about 190 degreesFahrenheit.
 11. The system of claim 1, wherein the surfactant comprises:a detergent; and wherein the surfactant optionally comprises at leastone of an oxidizer and a bleaching agent.
 12. The system of claim 1,additionally comprising: a second turbo washer subsequent to the atleast one washing device, the second turbo washer being configured torinse the ground film.
 13. The system of claim 12, additionallycomprising: a first turbo dryer located intermediate the at least onewashing device and the second turbo washer, the first turbo dryer beingconfigured to remove moisture from the ground film.
 14. The system ofclaim 1, additionally comprising: a hydrocyclone located subsequent tothe at least one washing device, the hydrocyclone being configured tofurther separate contaminates from the ground film and further separatelayers of the ground film.
 15. The system of claim 14, additionallycomprising: a third friction washer located intermediate thehydrocyclone and the at least one dryer.
 16. The system of claim 1,wherein the at least one dryer comprises: a second turbo dryer; and athird turbo dryer.
 17. The system of claim 1, additionally comprising: afilm flake buffer silo located intermediate the at least one dryer andthe additional processing apparatus, the flakes of film beingtemporarily deposited into the film flake buffer silo.
 18. The system ofclaim 1, wherein the additional processing apparatus comprises: aplastcompactor arranged to heat and further reduce moisture contained inthe flakes of film, the plastcompactor fusing the flakes of film intoformations of film; and a second granulator located subsequent to theplastcompactor, the second granulator reducing the formations of filminto the granulated objects of near-virgin quality blown film product.19. The system of claim 1, wherein the elements of the system arearranged and configured to produce granulated objects of blown filmproduct having a gel count that does not exceed 1,000 gels on a 12 inchby 12 inch square segment.
 20. The system of claim 1, additionallycomprising: a conveyor network configured to interconnect the variouselements of the systems, wherein the conveyor network comprises at leastone of a storage conveyor, an inclines conveyor, a discharge belt, atransport screw, and a pneumatic transport tube.
 21. A system forprocessing a supply of post-consumer scrap linear low densitypolyethylene film or low density polyethylene film into near-virginquality blown film product, comprising: a shredder configured to tearthe supply of post-consumer scrap linear low density polyethylene filmor low density polyethylene film in the shredder, wherein surface areaof the film is exposed, including delaminating the film; a first washingscrew that wets delaminated film received from the shredder; aprewash/sink/float tank apparatus that removes contaminates from thedelaminated film received from the first washing screw, theprewash/sink/float tank apparatus separating high density materials fromthe delaminated film; a grinder configured to grind the wetted,delaminated film into ground film to reduce it in size; a washing deviceconfigured to wash the ground film to remove additional contaminatesfrom the ground film, wherein the washing device contains hot water at atemperature of between about 140 degrees Fahrenheit and about 190degrees Fahrenheit, and wherein the washing device comprises: a firstfriction washer that receives the ground film from the grinder; a secondwashing screw located subsequent to the first friction washer; a firstturbo washer located subsequent to the second washing screw; and asecond friction washer located subsequent to the first turbo washer;wherein one of the first washing screw, the prewash/sink/float tankapparatus, and the washing device includes a surfactant; a second turbowasher subsequent to the washing device, the second turbo washer beingconfigured to rinse the ground film; a first turbo dryer locatedintermediate the washing device and the second turbo washer, the firstturbo dryer being configured to remove moisture from the ground film; ahydrocyclone located subsequent to the first turbo dryer, thehydrocyclone being configured to further separate contaminates from theground film and further separate layers of the ground film; a thirdfriction washer located subsequent to the hydrocyclone; at least oneadditional turbo dryer located subsequent to the third friction washer,at least one additional turbo dryer being configured to dry the groundfilm into flakes of film containing not more than 10% by weight of watercontent; a plastcompactor located subsequent to the second and thirdturbo dryers, the plastcompactor being arranged to heat and furtherreduce moisture contained in the flakes of film, the plastcompactorfusing the flakes of film into formations of film; and a secondgranulator located subsequent to the plastcompactor, the secondgranulator reducing the formations of film into the granulated objectsof near-virgin quality blown film product.